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home brew e-bike
#1
One of my projects is making a e-bike with my26650 A123 cells.

I bought the parts from the UK 1000W 48V motor+controller.
I will have dual speed control -PAS and tumbtrottle.

I started with single speed On-One that I build in 2010

 

specs:
One-one steel frame+fork
Race-face cranck set
Xt bottom bracket
Avid mechanical disk brake cable routing through the fork 180mm disk
mini steel steer and random alloy Stem
DT-swiss DH hubs spokes and rims small road tires.
beefy SS chain.
38T front ring
11T rear

I will need to upgrade since the 1000W engine will give loads of POWER  Big Grin





 motor wiring and display installed.
48T front ring
16T rear



 

The display a KT-LCD1


 

The PAS system is installed between the bottom bracket and frame. 
The magnet disk is mounted on the square axle.






The motor controller is a 48V Mxus sold by Cyclotricity UK
The Motor is marked Cyclotricity marked as 250W restricted. (actual 350W/3000W MXUS)


  

54.4 V battery pack "installed"

Test set up is ducked-taped to go, peddle assist set to "5" GOO!

And it's F*cking scary fast!! Tongue

It's restricted to 250W but still goes 49km/p when peddling hard.
It's possible to fully unlock the 1000W Angel .

Next: 
- making a battery box with charge plug mid frame
- integrate the BMS in the box.
- upgrade the disk brakes to hydraulic Front and Back (instead of the mechanical frontbrake)
- front suspension might be nice  Shy
hbpowerwall, zag2me, BlueSwordM And 1 others like this post
Greetz Dennis

http://www.verticallife.nl

Current Of-grit setup
5 230Wp canadian Solar panels
2 Voltmaster 270Ah 12V Battery's
1 Outback flexmax80
1 Phoenix 3000 inverter
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#2
So I started my Battery box.


3 aluminium profile's


sized to fit the frame


curing the epoxy


Glasfiber reinforced polyester plates

and glasfiber tape + epoxy resin to seal it all up

 
battery trial fit with controller 

 
status so far:
its working just need to fix the components inside the box against movement.
and I need to smoothen the box 
and make a lid/cover

p.s. Yes thats my dogs "Castle" in the background
hbpowerwall likes this post
Greetz Dennis

http://www.verticallife.nl

Current Of-grit setup
5 230Wp canadian Solar panels
2 Voltmaster 270Ah 12V Battery's
1 Outback flexmax80
1 Phoenix 3000 inverter
Reply
#3
Following. I also want an e-bike some day Smile
The Ultimate DIY Solar and build place
YouTube / Forum system setup / My webpage  Diy Tech & Repairs

Current: 10kW Mpp Hybrid | 4kW PIP4048 | 2x PCM60x | 83kWh LiFePo4 | 10kWh 14s 18650 |  66*260W Poly
Upcoming: 14S 18650~30kWh | Automatic trip breakers, and alot more
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#4
My e-bike i up and running
I only need to make a lid for the battery box and a BMS/charger for the battery.

 

I like to make a bigger battery pack now it 17P2S 54,6V
Or I place 2 battery packs with a switch so I can can use only one at the time.

Other feature will be a integrated LED front light from eBay.
And I like to have a USB charger for my phone not sure how to connect it to the 54V battery..
hbpowerwall likes this post
Greetz Dennis

http://www.verticallife.nl

Current Of-grit setup
5 230Wp canadian Solar panels
2 Voltmaster 270Ah 12V Battery's
1 Outback flexmax80
1 Phoenix 3000 inverter
Reply
#5
I think you got the P and S mixed up. 17S2P So 54.6V. What is the capacity of those A132 26650 Cells?
Reply
#6
(10-03-2017, 01:39 PM)jdeadman Wrote: I think you got the P and S mixed up.    17S2P  So 54.6V.   What is the capacity of those A132 26650 Cells?

Big Grin atlas some one is paying attention . 2P17S Tongue
Greetz Dennis

http://www.verticallife.nl

Current Of-grit setup
5 230Wp canadian Solar panels
2 Voltmaster 270Ah 12V Battery's
1 Outback flexmax80
1 Phoenix 3000 inverter
Reply
#7
I build one pack for my bike.
48V 16S-2P with the same LIFEPO4 A123 3.3 V cells as I'm using in my power wall.

I bought a cheap chinees LIFEPO4 BMS:
https://www.ebay.nl/itm/48V-45A-LiFePo4-...2749.l2649

It's a bit strange it only has a B- (battery minus and) C- (charging minus).
But it works.
I discharged the packing it stopped exactly with discarding at 42.5 Volt.
charged it up to 61,5 Volt and it holds the charge Big Grin .



Let's hope it keeps performing well.
Greetz Dennis

http://www.verticallife.nl

Current Of-grit setup
5 230Wp canadian Solar panels
2 Voltmaster 270Ah 12V Battery's
1 Outback flexmax80
1 Phoenix 3000 inverter
Reply


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